Direct bottomed article of footwear with a film

ABSTRACT

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Application Ser.No. 62/628,134, titled “Direct Bottomed Article of Footwear with aFilm,” and filed Feb. 8, 2018. The entirety of the aforementionedapplication is incorporated by reference herein.

TECHNICAL FIELD

Directed to an article of footwear with a direct attached sole.

BACKGROUND

Traditionally, an article of footwear is formed with an upper and a solethat are joined subsequent to the formation of each. This processincludes the positioning and aligning of the separate components to thenbe bonded with various techniques, such as an adhesive.

BRIEF SUMMARY

Aspects hereof contemplate an article of footwear having an upper thatis directly attached with the sole. The sole has a film extending upsidewalls of the sole to a film edge that is prior to the sidewall andthe upper joining. Method of manufacture of the article of footwearincludes steps of positioning a film over a mold cavity and thensecuring the film to the mold. The film is heated and then drawn intothe mold cavity under a vacuum. The film forms a liner of the moldcavity. A foam composition is injected into the lined mold cavity. Asthe foam composition expands, the foam composition interacts with andmechanically engages with the upper that is positioned at the moldcavity to allow for the mechanical engagement that results in the directattach of the sole to the upper. The film is then trimmed from the solesidewalls at the film edge.

This summary is provided to enlighten and not limit the scope of methodsand systems provided hereafter in complete detail.

DESCRIPTION OF THE DRAWINGS

The present invention is described in detail herein with reference tothe attached drawing figures, wherein:

FIG. 1 depicts an article of footwear, in accordance with aspectshereof;

FIG. 2 depicts a cross section of the article of footwear from FIG. 1,in accordance with aspects hereof;

FIG. 3 depicts an exploded view of the article of footwear from FIG. 1,in accordance with aspects hereof;

FIG. 4 depicts an exemplary system for manufacturing the article offootwear from FIG. 1, in accordance with aspects hereof;

FIG. 5 depicts a mold for forming the article of footwear from FIG. 1,in accordance with aspects hereof;

FIG. 6 depicts the mold from FIG. 5 having an outsole positionedtherein, in accordance with aspects hereof;

FIG. 7 depicts a first alternative example of a film secured to the moldof FIG. 5, in accordance with aspects hereof;

FIG. 8 depicts a cross-sectional view of the first example of a filmsecured to the mold from FIG. 7 after the film has been drawn into themold cavity as a liner, in accordance with aspects hereof;

FIG. 9 depicts a second alternative example of a film secured to themold of FIG. 5, in accordance with aspects hereof;

FIG. 10 depicts a cross-sectional view of the second example of a filmsecured to the mold from FIG. 9 after the film has been drawn into themold cavity as a liner, in accordance with aspects hereof;

FIG. 11 depicts a third alternative example of a film secured to themold of FIG. 5, in accordance with aspects hereof;

FIG. 12 depicts a cross-sectional view of the third example of a filmsecured to the mold from FIG. 11 after the film has been drawn into themold cavity as a liner, in accordance with aspects hereof;

FIG. 13 depicts a fourth alternative example of a film secured to themold of FIG. 5, in accordance with aspects hereof;

FIG. 14A depicts a cross-sectional view of the fourth example of a filmsecured to the mold from FIG. 13 after the film has been drawn into themold cavity as a liner, in accordance with aspects hereof;

FIG. 14B depicts an alternative cross-sectional view of a the magneticring after the film has been drawn into the mold cavity as a liner, inaccordance with aspects hereof;

FIG. 15 depicts a heater heating the film, in accordance with aspectshereof;

FIG. 16 depicts the film drawn into the mold cavity to form a liner, inaccordance with aspects hereof;

FIG. 17 depicts a lasted upper, in accordance with aspects hereof;

FIG. 18 depicts the lasted upper of FIG. 17 positioned at the mold ofFIG. 16, in accordance with aspects hereof;

FIG. 19 depicts the mold and upper of FIG. 18 in a closed configurationwith polymeric foam composition being injected for a direct bottomingprocess, in accordance with aspects hereof;

FIG. 20 depicts the article of footwear created at the FIG. 19 with aportion of the film to be trimmed, in accordance with aspects hereof;

FIG. 21 depicts a trimming operation of the article of footwear fromFIG. 20, in accordance with aspects hereof;

FIG. 22 depicts an alternative and optional process of inserting aninsert into the mold cavity prior to direct bottoming an upper, inaccordance with aspects hereof; and

FIG. 23 depicts a flow chart illustrating an exemplary method ofmanufacturing an article of footwear, in accordance with aspects hereof.

DETAILED DESCRIPTION

Traditional methods of manufacturing an article of footwear include avariety of processes that are performed in sequence to result in theformation of the footwear (e.g., shoe, cleat, sandal, slipper, andboot). In an effort to reduce manufacturing time, manufacturing cost,and potential defects, an elimination or consolidation of steps beingperformed is sought. Traditional shoe manufacturing, such as an athleticshoe, includes the formation of a footwear upper (“upper”), the portionof the shoe that secures the shoe to a wearer's foot. The upper is thenjoined with a footwear bottom unit, which is commonly referred to as asole. The sole may be comprised of a variety of materials and/orcomponents, such as an outsole, a midsole, and/or an insole. However,any combination of materials/components may be formed and produced inconnection with the manufacture of a shoe.

Traditional manufacturing techniques for a shoe include the joining of aformed upper with a formed sole. This joining may be accomplishedthrough use of an adhesive applied to one or more surfaces to be joinedof the upper and the sole and then positioning the upper and the sole incontact for the adhesive to couple the components into an article offootwear. This step of joining the upper and the sole introduces amanufacturing process that adds time, cost, and the potential fordefects. For example, if the adhesive extends beyond an area to bejoined (e.g., beyond a biteline of the upper), the adhesive may bevisible and cause a degradation of the aesthetic characteristics of theshoe. Further, the sole and the upper may not be properly aligned duringthe joining causing a defective shoe. Additionally, the joining processintroduces adhesives or other bonding materials into the footwear thatcan affect performance and feel of the finished article. Further yet,the adhesive or bonding material adds material cost and additionalmanufacturing inventory to the planning and production for the shoe.

As a result, a concept of direct bottoming (or sometimes referred to asdirect attach) is provided. Direct bottoming, for purposes of thepresent disclosure, includes the formation of at least a portion (e.g.,a foamed midsole) of the sole with the upper present and results in thesole being joined with the upper. For example, it is contemplated that amolding operation is performed where a polymeric foam composition (e.g.,polyurethane “PU”) is injected into a mold cavity wherein a plantarportion (e.g., under foot portion) of the upper is positioned at themold cavity. As the polymeric foam composition expands during a foamingprocess, the polymeric composition interacts with the plantar region ofthe upper to form at least a mechanical engagement between the polymericfoam composition and the upper material. As the polymeric foamcomposition cures, the physical engagement between the polymeric foamcomposition and the upper forms a bond coupling the two together withsufficient bond strength for use as an article of footwear. A directbottoming process allows for the reduction of materials and or stepsduring the method of manufacturing. For example, the direct bondingbetween the polymeric foam composition as it cures and the upper caneliminate the use of an adhesive, in some aspects. Further, as the soleis molded in the presence of the upper, alignment, size, and fit of thesole and upper are better ensured.

Direct bottoming of an article of footwear does, however, adjustprocessing steps for the forming of the footwear relative to atraditional manufacturing process. For example, as the sole is notformed until it is joined with the upper, refinements and processing ofthe sole is done in the presence of the upper. Tooling, such as a mold,used when forming the direct attached sole may create tooling marks inthe sole. A tooling mark is an unintended feature that results from themanufacturing of the sole. Tooling marks may result from intersectionsof tooling portions (e.g., a medial ring intersecting with a lateralring to result in a line or other feature at the junction of the toolingportions). The tooling marks may be addressed through buffing, cutting,polishing, and other operations to reduce or eliminate the presence ofthe tooling marks. However, in direct bottoming manufacturing, the upperis present during the rectification steps to the sole, which may exposethe upper to opportunities for damage or other defects.

Aspects hereof contemplate forming an article of footwear through adirect bottoming process that limits unintended tooling-inducedfeatures, allows for customization in a sequential manufacturingprocess, reduces materials, and eliminates manufacturing processes.

Specifically, turning to FIG. 1, which depicts an article footwear 100,in accordance with aspects hereof. The article of footwear 100 is formedwith an upper 102 comprising a medial side 106, a lateral side 108, atoe end 110, a heel end 112, and a plantar region 114 extending betweenthe medial side 106, the lateral side 108, the toe end 110, and the heelend 112. The article of footwear also includes a sole 104 having amedial side 116, a lateral side 118, a toe end 120, a heel end 122, anupper-facing surface 123 extending between the medial side 116, thelateral side 118, the toe end 120, and the heel end 122, a ground-facingsurface 124 opposite the upper-facing surface 123, a medial sidewall 126extending between the ground-facing surface 124 and the upper-facingsurface 123 along the medial side 116, and a lateral sidewall 128extending between the ground-facing surface 124 and the upper-facingsurface 123 along the lateral side 118. The sole 104 includes apolymeric foam composition 130 forming at least a portion of theupper-facing surface 123 and mechanically engaged with the upper plantarregion 114. The sole also comprised of a polymeric film composition 132forming at least a portion of the medial sidewall 126 from theground-facing surface 124 toward the upper 102 at a medial film edge 134and also forming at least a portion of the lateral sidewall 128 from theground-facing surface 124 toward the upper 102 at a lateral film edge136. There is at least 1 mm between the upper-facing surface 123 at themedial sidewall 126 and the medial film edge 134 forming a medialexposed portion 135 and there is at least 1 mm between the upper-facingsurface 123 at the lateral sidewall 128 and the lateral film edge 136forming a lateral exposed portion 137. The article of footwear 100 isalso comprised of an outsole 138, in the depicted example.

As will be provided in greater detail herein, the sole 104 is formedfrom the polymeric foam composition 130 that is direct attached to theupper 102 during the sole 104 forming process. The sole 104 alsoincludes the polymeric film composition 132 that forms an exteriorsurface of the sole along portions of the sidewall(s). This polymericfilm composition 132 is effective to provide a variety of differentvisual characteristics to the article of footwear 100, such asvariations in coloration, texture, and graphics, and other finishes.Further, it is contemplated that the polymeric film composition 132provides a protective barrier to the polymeric foam composition 130 fromthe environment. For example, the polymeric film composition 132 mayprotect against hydrolysis and ultraviolet radiation effects on thepolymeric foam composition 130. Further yet, the polymeric filmcomposition 132 reduces unintended tool marking features from beingformed by the manufacturing tools as the polymeric film compositionserves as a liner between the tooling (e.g., a mold 200 of FIG. 3) andthe polymeric foam composition 130. The liner formed by the polymericfilm composition 132 is effective to transition between tooling portionsthat would otherwise create a tooling mark feature that wouldsubsequently be processed away.

Exposed regions, such as the medial exposed portion 135 and the lateralexposed portion 137, provide several advantages to the aspectscontemplated herein. For example, the exposed regions are a region atwhich the polymeric film composition 132 is not present on an exteriorsurface of the article of footwear 100. Terminating the polymeric filmcomposition 132 at the film edges, such as the medial film edge 134 andthe lateral film edge 136, allows for an efficient and effectivetermination of the polymeric film composition 132. For example, theexposed region provides area in which a trimming operation may beperformed on the polymeric film composition 132 (as best seen in FIG. 19hereinafter). Without the exposed region of at least 1 mm between thefilm edge and the upper, a cutting tool may not properly access andcleanly cut excess polymeric film composition from the polymeric foamcomposition. Further, the exposed region provides more opportunities fordesign flexibility in the article of footwear. Having the exposed regionbetween the polymeric film composition 132 and the upper 102 allows fora difference in visual characteristics, such as material, texture,color, reflectance, graphics, and the like. The footwear may thereforebe designed to have a variety of appearances as a result of theinclusion of the exposed region. An exposed region may extend around theentire article of footwear or it may extend only along some portions,such as the medial side and the lateral side. The exposed portion mayhave a constant band thickness or the exposed portion may have avariable band thickness.

The polymeric foam composition 130 may be any polymeric composition.Foam is a cellular structure with either open celled or closed cellstructures of polymeric composition and voids, such as gas voids. In anexemplary aspect, the polymeric foam composition is a polyurethane(“PU”) composition. The PU may be chemically foamed or mechanicallyfoamed during the curing process to result in a polymeric foamedcomposition. The polymeric foam composition may include additionalcomponents, such as colorants and other additives. While PU compositionis specifically listed, other polymeric compositions are contemplated,such as ethylene-vinyl acetate, low-density polyethylene, nitrilerubber, polychloroprene, polyimide, polypropylene, polystyrene,polyvinyl chloride, silicone, and the like. However, as will bediscussed in greater detail, bonding affinity between the polymeric foamcomposition 130 and the polymeric film composition 132 during the curingphase of the polymeric foam composition 130 drives manufacturingefficiencies. An exemplary combination of materials that have sufficientbonding affinity are PU as the polymeric foam composition 130 andthermoplastic polyurethane (“TPU”) as the polymeric film composition132.

The polymeric film composition 132 may be any polymeric composition.Film is a thin layer of polymeric composition having a thickness in arange of about 50 microns to about 600 microns. In an exemplary aspect,the polymeric film composition prior to being inserted into a moldcavity (or subsequent), as will be discussed hereinafter, has athickness in a range of about 100 microns to about 400 microns. Withinthis exemplary range, the polymeric film composition 132 providessufficient durability to serve as an exterior surface on an article offootwear, has sufficient resilience to be formed as a liner of a moldcavity during manufacturing, and is sufficiently thick to obscuretooling irregularities that would otherwise generate unintended toolmarkings in the polymeric foam composition 130, for example. Otherthickness ranges are contemplated and vary with a polymeric compositionselected. In an exemplary aspect the polymeric film composition 132 is aTPU composition. Further, in an exemplary aspect, the polymeric filmcomposition 132 is a TPU composition having a thickness of 100 to 300microns. Further yet, in an exemplary aspect the polymeric filmcomposition 132 is a non-porous film capable of being formed as a linerin a mold cavity under vacuum.

The polymeric film composition 132 may have a variety of visualcharacteristics. Visual characteristics include, but are not limited to,material, sheen, coloration, reflectance, texture, graphicalpresentation, and the like. As will be appreciated throughout, thepolymeric film composition 132 may be changed from one shoe to the nextshoe during a continuous manufacturing process. As a result during acontinuous production run, shoes having different visual characteristicsmay result from a common manufacturing process without significantalteration of the manufacturing mechanisms. Instead, it is contemplatedthat a different polymeric film composition may be provided during themanufacturing process. This convenience and flexibility allows forcontinued use of the capital equipment while still offering customizedmanufacturing options. For example, a first shoe may be produced with afirst polymeric film composition having a first visual characteristicand the subsequent shoe to be produced without stopping production mayuse a second polymeric film composition having a different visualcharacteristic.

The upper 102 may be formed from any material, such as animal-basedfibers (e.g., wool, hair, silk), plant-based fiber, and/or syntheticfibers. In an exemplary aspect, the upper 102 is formed from a textilematerial having one or more fibers in the plantar region 114. The fibersin the plantar region 114 provide a surface to which the polymeric foamcomposition 130 may interact and mechanically bond therewith. Forexample, the upper 102 may be formed from a knit, woven, braided,non-woven, and the like textile comprising one or more yarns, filaments,and/or fibers that provide a surface amenable for direct bottoming. Insome aspect, the upper 102 in at least the plantar region 114 includes aporous structure that allows a yet-to-be cured (e.g., fluid-likeproperties that allow the polymeric composition to flow around and/orthrough the porous structure) polymeric composition to infiltrate and/orat least partially encapsulate some of the fibrous elements forming thetextile. Once encapsulated, the polymeric composition cures to a solidor more resilient state (e.g., cures as a foamed polymeric composition)forming a mechanical bond with the upper 102 through the interactionwith the encapsulated fibrous elements. Further, it is contemplated thata chemical bond may additionally or alternatively be formed by thepolymeric composition and the upper as the polymeric composition curesto a foamed polymeric composition state. The chemical bond iscontemplated when compositions having an affinity for chemical bonding,such as an upper having PU and/or TPU compositions forming at least aportion of the plantar region 114 (e.g., a knit upper having TPU and/orPU yarns integrally knit in at least the plantar region 114) and thepolymeric foam composition 130 comprises a PU composition. In thisexample, the upper and the polymeric foam composition form a directbottom bond through mechanical engagement and/or chemical engagement ofthe various compositions.

Similarly, it is contemplated that a chemical bond may be formed betweenthe polymeric foam composition 130 and the polymeric film composition132 to join the two compositions. As such, it is contemplated that thepolymeric foam composition 130 and the polymeric film composition 132are selected to have a sufficient chemical bonding affinity to resistdelamination. An exemplary combination of material compositions withsufficient delamination resistance includes the polymeric foamcomposition 130 as a PU composition and the polymeric film composition132 as a TPU composition. Other compositions are contemplated.

Returning to FIG. 1, the article of footwear 100 is depicted as anathletic shoe; however, it is contemplated that any type of article offootwear may result from aspects provided herein. Of focus in thefollowing discussions are the sole 104 and the compositions of the sole104 at different locations. Specifically, the polymeric film composition132 is depicted as extending in a superior direction from theground-facing surface 124 toward the upper 102. In actuality for thespecific configuration provided in FIGS. 1-3, the polymeric filmcomposition 132 is a continuous film material extending across theground-facing surface 124 and forming the exterior of that surface whilecontinuing, uninterrupted, up the medial sidewall 126 and the lateralsidewall 128. Therefore, in this example, the polymeric film composition132 forms the exterior surface of the sole 104 from the film edge (e.g.,the medial film edge 134 and the lateral film edge 136) inferiorly. Theoutsole 138 may optionally be secured to the sole 104 in some aspects tothen form an exterior surface of the article of footwear 100 at aground-contacting region. As used herein, anatomical relational terms,such as superior, inferior, proximal, distal, medial, lateral, and thelike are in relation to an article of footwear in a traditional as-wornconfiguration on a user in and standing position. Therefore an inferiordirection extends towards a traditional ground-contacting surface and asuperior direction extends in a direction more proximal to the wearer inthe as-worn configuration.

The exposed regions of the sole 104, such as the medial exposed portion135 and the lateral exposed portion 137, are at least a 1 mm bandextending between the upper 102 intersection with the sole 104 and thefilm edge. As provided previously, the exposed region provides variousadvantages to the examples provided herein. For example, ease oftrimming the polymeric film composition 132 with reduced interference ofthe upper 102, design flexibility with variations in visualcharacteristics of between the upper 102, the exposed region, and thepolymeric film composition 132. The exposed region may have a lengthextending between the upper 102 and the film edge of any length.However, in an exemplary aspect the exposed region has a length of atleast 1 mm. In an additional exemplary aspect the length is at least 1mm and less than 10 mm. In yet another exemplary aspect, the exposedregion length is between about 2 mm and about 4 mm. The provided rangeof exposed area length extending between the upper and the film edgeprovides sufficient area to allow for trimming operations while stillproviding sufficient coverage and protection of the polymeric foamcomposition 130 by the polymeric film composition 132.

FIG. 2 depicts a cross section of the article of footwear 100, inaccordance with aspects hereof. The upper 102, the sole 104, and theoutsole 138 are illustrated. The sole 104 is formed from the polymericfoam composition 130 and the polymeric film composition 132. The sole104 has angled sidewalls, as seen in FIG. 2. Specifically, a firstdistance 144 at the ground-facing surface 124 is greater than a seconddistance 146 at the upper-facing surface 123 in this medial to lateralcross section view. The first distance 144 and the second distance 146are measured from the medial side 116 to the lateral side 118. An angledsidewall with direct bottomed footwear is possible, in an exemplaryaspect, as a result of the polymeric film composition 132 serving as aliner to the mold cavity for easier release of the sole 104 therefromrelative to a non-liner configuration.

As also depicted in FIG. 2, the polymeric film composition 132 extendsunderfoot forming the ground-facing surface 124 of the sole 104. As willbe appreciated in FIGS. 7-16, the polymeric film composition 132 extendsunderfoot to form a liner for a mold cavity prior to the mold cavityreceiving the polymeric composition that will foam as the polymeric foamcomposition 130. In aspects provided, the polymeric film composition 132is formed into a liner through use of vacuum pressure drawn through themold cavity and, in a specific example, through a bottom plate of themold cavity that forms the ground-facing surface. To effectively drawthe polymeric film composition 132 with a vacuum has the polymeric filmcomposition 132 as a continuous film that extends over the mold cavityand is drawn down into the mold cavity while maintaining continuity toensure a pressure differential (e.g., lower pressure created by thevacuum between the mold cavity and the film and a relatively higherpressure on the opposite surface of the film at atmospheric pressure)that forms the films to the mold cavity surfaces. Therefore, thepolymeric film composition 132 extends across the ground-facing surface124 from the sidewalls.

The polymeric foam composition 130 extends as a continuous foamcomposition from the polymeric film composition 132 on the ground-facingsurface 124 and the sidewalls to the upper-facing surface 123 at alocation of mechanical engagement with the upper 102. While notdepicted, it is contemplated that one or more inserts may beencapsulated in the sole 104. For example, as will be depicted in FIG.20, it is contemplated that an insert (e.g., air bag, stability element,support element, foam element) may be positioned in the mold cavityhaving the polymeric film composition 132 as a liner and prior to thepolymeric foam composition 130 being inserted. The insert may bepositioned within the mold cavity prior to the positioning of the upper102 at the mold. Alternatively, it is contemplated that the insert maybe positioned on the upper 102, such as the plantar region 114, toposition the insert into the mold cavity when the upper 102 ispositioned at the mold, as will be described hereinafter. Regardless ofthe initial positioning of the insert, this encapsulated insert ismaintained in a relative position of the sole 104 by the compositionsforming the sole 104 and provides varied functional characteristics(e.g., impact attenuation, resilience, support) at a specified locationof the sole 104.

The article of footwear 100 as depicted in FIG. 2 shows the upper 102lateral side 108, the medial side 106, and the plantar region 114. Atthe plantar region 114 the polymeric foam composition 130 ismechanically engaged with the upper 102. While not depicted, in someaspects it is contemplated that the cross sectional view will depicts atleast a portion of the polymeric foam composition 130 extending into thematerial forming the plantar region 114 forming a mechanical bond. Thesole 104 is depicted with the lateral exposed portion 137 and the medialexposed portion 135. The exposed portions extend between the upper 102and the respective lateral film edge 136 and the medial film edge 134.Continuing in an inferior direction from the film edge, the polymericfilm composition 132 extends down along the sidewalls, such as themedial sidewall 126 and the lateral sidewall 128, to form theground-facing surface 124. As depicted in FIG. 2, the polymeric filmcomposition 132 is a continuous and relatively non-porous material thatis able to be drawn as a liner into a mold cavity through vacuumpressure. The outsole 138 is depicted as being joined with the polymericfilm composition 132 at the ground-facing surface 124. A first distance144 extending between the medial side and the lateral side at theground-facing surface 124 is provided. A second distance 146 extendingbetween the medial side and the lateral side at the upper-facing surface123 is provided. The first distance 144 is greater than the seconddistance 146 as the medial sidewall 126 and the lateral sidewall 128angle towards one another in the superior direction (i.e., away from theground-facing surface 124 towards the upper-facing surface 123).

FIG. 3 depicts an exploded view of the article of footwear 100 prior totrimming the polymeric film composition, in accordance with aspectshereof. The upper 102, the polymeric foam composition 130, the polymericfilm composition 132, and the outsole 138 are illustrated. The sole 104is comprised of the polymeric foam composition 130 and the polymericfilm composition 132, in this exemplary aspect. While the outsole 138 isdepicted, it is optional in some exemplary aspects. It is contemplatedthat the polymeric film composition 132 may serve as a ground contactingsurface in some examples. Further, it is contemplated that the polymericfilm composition 132 may have traction elements (e.g., lugs, treads)integral to the film or formed into the film during the moldingoperation with the polymeric foam composition 130, in yet anotherexemplary aspect.

The polymeric film composition 132 is depicted having the trimmedportion 133 extending from what will be the film edges, such as themedial film edge 134 and the lateral film edge 136 following a trimmingoperation. The outsole is depicted having a plurality of the outsoleapertures 140. As previously discussed, the outsole aperture 140provides a conduit through which vacuum may transfer from the bottomplate to the mold cavity to effectively draw the polymeric filmcomposition 132 into the mold cavity. In an exemplary aspect, theoutsole 138 is comprised of a plurality of the apertures extendingthrough the outsole 138 to allow for an even and complete draw of thepolymeric film composition 132 into the mold cavity.

While a specific size, shape, and configuration of the variouscomponents forming the article of footwear 100 are provided in FIGS.1-3, they are illustrative in nature. Instead, it is contemplated thatany size, shape, configuration and style may be associated with any oneor more of the components and features of those components. For example,the upper 102 and/or the sole 104 may be and size, shape, andconfiguration. Further, the outsole 138 may be omitted or altered invarious aspects. Further yet, as previously discussed, it iscontemplated that one or more inserts may be provided in connection withdirect bottomed footwear. The insert may be relatively positioned in avariety of ways. For example, the insert may be positioned between anoutsole and a film layer. The insert may be positioned between a filmlayer and a foam material. The insert may be positioned between a foammaterial and the upper. A plurality of inserts may be positioned at avariety of locations and relative positions. Further yet, additionalelements may be included, such as a sock liner, insole, or othercomponents used in connection with an article of footwear. Additionally,it is contemplated that a primer, adhesive, or other bonding supplementmay be used in connection with any of the components of the article offootwear 100 to aid in assembly.

FIG. 4 depicts an exemplary system having a mold 200 shown incross-section for making an article of footwear, in accordance withaspects hereof. The mold 200 is comprised of an inner ring 204 (alsoreferred to as an “inner ring mold” hereinafter), an outer ring 206(also referred to as an “outer ring mold” hereinafter), and a bottomplate 208. However, while a specific configuration, such as an innerring and an outer ring, is depicted in connection with the figures, itis contemplated that alternative tooling and configurations may insteadbe implemented. The system also includes a vacuum source 230. The vacuumsource 230 is effective to generate a vacuum, such as negative pressurerelative ambient conditions. The vacuum source 230 may generate thevacuum through a variety of methods, such as a fan, impeller, coanda,venturi, and the like. The vacuum source 230 is operatively coupled,such as through tubing, with one or more components, such as the bottomplate 208. The operative coupling between the vacuum source and thebottom plate 208 allows for vacuum to be drawn through the bottom plate208 at one or more bottom plate vacuum ports 222 that extend through toa bottom plate top surface that forms a molding surface for the moldcavity. The bottom plate vacuum ports 222 allow for vacuum to be drawnthrough the mold cavity 202 and to pull in the polymeric filmcomposition 132 to form a liner of the mold cavity 202.

In an optional configuration depicted in FIG. 4, and further illustratedin FIGS. 11-12 hereinafter, the vacuum source 230 (or a separate vacuumsource) may be operatively coupled with the mold 200 in a manner tosecure the polymeric film composition 132 prior to the film being drawninto the mold cavity 202. In this example, the vacuum source 230 isoperatively coupled with the inner ring 204 to provide a vacuum at innerring vacuum port 224, which will be discussed in greater detail at FIGS.11-12.

The system of FIG. 4 also includes a heat source 228. The heat source228 is effective to heat the polymeric film composition 132 to aid inthe polymeric film composition 132 being drawn into the mold cavity 202by vacuum. The heat source 228 may be any heat source, such as a radiantheat source. The heat source 228 may operate with electrically resistiveelements, infrared radiation (e.g., near and/or far range), and/or thelike. For example, the heat source 228, as seen in FIG. 13, may bepositioned in proximity to the polymeric film composition 132 and applya flash of thermal energy to the polymeric film composition 132 toincrease the temperature of the polymeric film composition 132 aboveambient temperature. In some examples the temperature is raised to atemperature above ambient temperatures but below a melting temperatureof the polymeric film composition 132. The increase in temperatureallows for the polymeric film composition 132 to more easily comply withthe mold cavity 202 as it is drawn in to the mold cavity 202. Easiercompliance of the polymeric film composition 132 while being drawnallows the polymeric film composition 132 to conform to the features ofthe mold surfaces with minimized polymeric film composition 132 creasingand other deformations. Further, application of the thermal energy tothe polymeric film composition 132 can reduce an amount of vacuum usedto line the mold cavity 202 with the polymeric film composition 132.

As will be discussed in connection with FIGS. 7-14, a variety ofconfigurations and techniques are contemplated for securing thepolymeric film composition 132 to the mold 200 during the vacuum drawingof the polymeric film composition 132 into the mold cavity 202.

The system of FIG. 4 also depicted a robotic arm 236. The robotic arm236 represents any conveyance mechanism (e.g., multi-axis robot, X-Yplane movement gantry). The robotic arm is effective to manipulate oneor more tools and or one or more components in the system of FIG. 4. Forexample, the robotic arm may be effective, in an exemplary aspect, toposition the polymeric film composition 132 on the mold 200 from a filmsource 238. The robotic arm may be adapted with a claw, vacuum pickuptool, adhesion tool, hook, and/or the like to secure the polymeric filmcomposition 132, move the polymeric film composition 132, and thenposition the polymeric film composition 132 at the mold 200 for beingdrawn into the mold cavity 202. Additionally or alternative, the roboticarm 236 is effective to position the heat source 228 at an appropriateposition relative the polymeric film composition 132 for heating thepolymeric film composition 132. Further yet, the polymeric filmcomposition 132 (or a variation thereof) may be effective to positionthe upper 102 relative to the mold 200 for the direct bottomingoperation.

The film source 238 may be an inventory of films, such as the polymericfilm composition 132, having varied characteristics. The variedcharacteristics may include varied visual characteristics, such ascolor, texture, reflectance, and the like. The film source 238 may alsoinclude an inventor of films have different physical attributes. Forexample, different compositions, different thicknesses, different sizes.For example, the film source 238 may include various sizes of polymericfilm compositions that are sized appropriate for a size or style offootwear being manufactured.

A material source 234 is a source of the polymeric foam composition 130.The material source 234 may be comprised of various compositions thatare mixed and interact as being injected into the mold cavity 202 by aninjector 232. The material source 234 may be comprised of a plurality ofsources, such as a separate source for different elements forming thepolymeric foam composition 130.

A vision system 256 is provided with the system of FIG. 4. The visionsystem 256 is effective to capture an image or plurality of images(e.g., video) of the mold and one or more components. The vision system256 may be used to ensure placement of components relative to thetooling or relative to other components. For example, the vision system256 may be effective to aid in the pick and place operations performedby the robotic arm 236. Further yet, the vision system 256 may beeffective to identify the tooling and therefore the appropriateprocesses and/or components to process. Additionally, the vision system256 may be used to evaluate quality metrics and to adjust processparameters or processes as a result of the determinations.

Returning to the mold 200, a variety of mold surfaces are present in themold cavity 202. For example, a first mold surface 210 is formed by atop surface of the bottom plate 208. A second mold surface 212 is formedby a combination of molding surfaces. For example, a medial sidewall 214of the inner ring 204 and a medial sidewall 216 of the outer ring 206may form the second mold surface 212. In different toolingconfigurations the second mold surface is formed from portions of thetooling that form the sidewalls of the sole. On the lateral side, alateral sidewall 218 of the inner ring 204 and a lateral sidewall 220 ofthe outer ring 206 form a sidewall molding surface of the mold 200. Theinner ring 204 is comprised of a top surface 226. The top surface 226 isa surface that supports the polymeric film composition 132 as it isdrawn into the mold cavity to form a liner of the mold cavity. The topsurface 226 is a location, in an exemplary aspect, of the inner ringvacuum port 224. In aspects depicted in FIGS. 9-10, the inner ring topsurface 226 is a surface for positioning a compression ring 246 around alip formed in the inner ring top surface 226 to secure the polymericfilm composition 132 to the mold through a compression fit prior todrawing the polymeric film composition 132 into the mold cavity 202.Further yet, as will be depicted in FIGS. 7 and 8, the inner ring topsurface 226 provides a securement location for one or more moldsecurements to extend through film apertures to secure the polymericfilm composition 132 to the mold 200.

A bottom plate actuator 258 is provided to linearly move the bottomplate 208 in an inferior and superior direction relative to the articleof footwear to be manufactured. The bottom plate actuator 258 may be ahydraulic, pneumatic, electric, or the like actuator. The bottom plateactuator 258 is effective to position the bottom plate at differentvertical positions depending on the process being performed, the articlebeing manufactured, and/or the materials being used. For example, assome polymeric compositions have different foaming reactions that havedifferent volume changes resulting, a different height of the bottomplate 208 relative to a location of the upper 102 may be desired andtherefore adjusted by the bottom plate actuator 258. Additionally, it iscontemplated that the bottom plate 208 is positioned at a first heightprior to injecting the polymeric foam composition 130 and then raised toa second height that is closer to the upper 200 after the polymeric foamcomposition 130 is injected. This changing of the bottom plate 208 afterinjection can be an effective mechanism to clear the injection run thatsupplies the material through the mold and/or to provide sufficientvolume for injecting the material the length of the mold cavity withvaried injections pressures without having the upper 102 interfere withthe injection stream, for example.

The system of FIG. 4 also includes ring actuators, such as the medialring actuator 260 and a lateral ring actuator 262. The medial ringactuator 260 and the lateral ring actuator 262 may be any actuator, suchas be a hydraulic, pneumatic, electric, or the like actuator. The ringactuators are effective to position the respective mold ring portionduring a manufacturing process. For example, and as shown in FIGS. 16and 17, the medial ring actuator 260 and the lateral ring actuator 262arc effective to secure the outer respective rings about the upper 102.The medial ring actuator 260 and the lateral ring actuator 262 move therespective outer rings of the mold to enclose the mold cavity with theplantar portion of the lasted upper 102. As the injected polymeric foamcomposition 130 expands during foaming, the mold 200 forms the polymericfoam composition into a net-sized, shape that is mechanically engagedwith the upper 102 because the polymeric foam composition 130 isenclosed in the mold cavity after the medial ring actuator 260 and thelateral ring actuator 262 move the outer rings into contact with theupper 102.

The mold 200 is contemplated that include the inner ring 204 andoptionally the outer ring 206. Further, as will be discussed in greaterdetail hereinafter, one or more polymeric film composition securementsare contemplated. The film securements include, but are not limited topins, a compression ring, a magnetic ring or plate, and/or a vacuumport. It is understood that the inner ring 204 in combination orindividually with the outer ring 206 may form the mold 200. When incombination as depicted in FIG. 4, the outer ring 206 slidably engageswith the inner ring 204 to position the lateral sidewall 220 and themedial sidewall 216 in appropriate positions to secure the upper and toform the exposed regions of the footwear sidewall. This movement of theouter ring 206 therefore presents a molding surface at an appropriateposition and it secures and forms a seal around the lasted upper for theinjection of the polymeric foam composition. In aspects where the outerring 206 is omitted, it is contemplated that the mold may still secureand seal around a lasted upper with a variety of techniques, such as asplit inner ring that is able to close around an upper positioned in amold cavity, as discussed herein with respect to the outer ring.

The various film securements will be discussed in detail in FIGS. 7-14Bhereinafter. However, in general, the various film securementconfigurations are effective to secure a polymeric film composition overa mold cavity to allow the polymeric film composition to be drawn intothe mold cavity and to then form a liner of the mold cavity. Therefore,variations on positions of elements comprising the film securement arecontemplated.

While specific components are depicted in FIG. 4, it is understood thatany of the components may be omitted. Further, it is contemplated thatany number of a listed component may be used in a system. Further yet,the components of FIG. 4 are exemplary in nature and are not limiting.

FIG. 5 depicts the mold 200 having the outer ring 206, the inner ring204, and the bottom plate 208 exposed, in accordance with aspectshereof. The mold 200 in FIG. 5 is in a configuration prepared for adirect bottoming process, as will be sequentially show in illustrativenature in the following figures.

FIG. 6 depicts the mold 200 with the outsole 138 placed on the bottomplate 208 within the inner ring 204, in accordance with aspect hereof.In this example, the outsole aperture 140 aligns with the bottom platevacuum port 222 allowing for a conduit through which vacuum may reachand affect the polymeric film composition 132. It is contemplated thatan adhesive or other bonding agent may be applied to the outsole 138 toaid in a bond between the outsole 138 and the polymeric film composition132. That adhesive or bonding agent may be applied at this step prior toforming the polymeric film composition 132 into a liner that is vacuumsecured to the outsole 138. This vacuum securing may aid in bonding theoutsole 138 and the polymeric film composition 132.

FIG. 7 depicts a first configuration for securing the polymeric filmcomposition 132 to the mold for being drawn into the mold cavity to forma liner, in accordance with aspects hereof. In this first configuration,a plurality of mold securements 250, as best seen in the cross sectionof FIG. 8, extend through film apertures 248 of the polymeric filmcomposition 132. This mechanical engagement by the mold securements 250anchors the polymeric film composition 132 to the mold 200 as it isdrawn into the mold cavity. Without an anchoring, regardless of type ofanchor configuration, the polymeric film composition 132 may be pulledbeyond the top surface of the mold and allow for a vacuum seal to bebroken, which would negate the effectiveness of the vacuum to pull thepolymeric film composition 132 into the mold cavity as a liner.

FIG. 8 depicts a cross section along line 8-8 of FIG. 7 after beingdrawn by vacuum to form a liner, in accordance with aspects hereof. Thepolymeric film composition 132 extends from the top surface 226 alongthe lateral sidewall 218, across the outsole 138 on the bottom plate 208to the medial sidewall 214 and up to the inner ring top surface 226 onthe medial side. The polymeric film composition 132 may be formed withthe film apertures 248 at predefined locations that ensure a consistenttension across the mold cavity based on a known distance between thepluralities of film apertures 248. Alternatively, the film apertures 248may be formed by the mold securement 250. For example, the moldsecurement 250 may puncture the polymeric film composition 132 at alocation selected by an operator. In this way, the amount of tensionresulting in the polymeric film composition 132 as it extends across themold cavity may be adjusted at the time of securement to accommodatevariations in materials, sizes, styles, and the like. Further, it iscontemplated that some of the film apertures 248 may be pre-formed andothers are formed by contact with their respective mold securement 250.

The mold securement 250 may be a pin, a hook, or any other protrusionextending from a portion of the mold 200 to which the polymeric filmcomposition 132 is proximate (e.g., contacts, near) and that is outsidethe mold cavity 252. The mold securement 250 may be integrally formedwith the mold 200 or it may be added after initial tooling generation isperformed. For example, one or more pins may be inserted into the mold200 to serve as mold securements 250.

FIG. 8 depicts the interaction of the inner ring 204 and the outer ring206. As the polymeric film composition 132 turns from the inner ringsidewalls, such as the medial sidewall 214, to the top surface 226, thesole sidewall molding surface is then formed by the outer ring 206 atthe medial sidewall 216. It is this medial sidewall 216 that forms themedial exposed portion 135 on the sole 104. Similarly, the lateralsidewall 220 forms the lateral exposed portion 137 of the sole 104.Having the inner ring 204 defining the mold surfaces supporting theliner formed by the polymeric film composition 132 and the outer ringdefining the mold surface of exposed portion, a film edge may be formedon the sidewall away from the upper 200, in an exemplary aspect.

It is understood that the dimensions of the outer ring sidewall surfacesmay be adjusted to change a width of exposed portion on the sole 104sidewall. For example, if a larger exposed portion is intended, the sizeof the outer ring sidewall may be increase. Conversely, if the size ofthe exposed portion is intended to be decreased, the size of the outerring sidewall is decreased.

FIG. 9 depicts a simplified securement of the polymeric film composition132 to the mold using compression, in accordance with aspects hereof.Specifically, a compression ring 246 is formed to compress the polymericfilm composition 132 around a perimeter element, such as the depictedlip, of the top surface 226. The compression ring 246 is formed from amaterial, such as steel, aluminum, polytetrafluoroethylene, and thelike. Because aspects contemplate heating the polymeric film composition132, the compression ring 246 is formed from a material that toleratesthermal cycles with temperatures exceeding 200 Celsius. Not only shouldthe compression ring 246 have tolerance for temperatures above 200Celsius, but the compression ring 246 should not degrade or deform withthe repeated thermal cycles. The compression ring 246 is sized toencircle the top surface 226 while also capturing and maintaining thepolymeric film composition 132 in the appropriate position. Therefore,appropriate sizing of the compression ring 246 that remains consistentthrough manufacturing cycles ensures a consistent securement of thepolymeric film composition 132.

Because the compression ring 246 extends around the perimeter in theaspects provided, the securements of the polymeric film composition 132is uniform around the mold cavity. Lack of uniformity in the securementcan result in creases or other deformations of the polymeric filmcomposition 132 as it is drawn into the mold cavity as a liner. Further,the polymeric film composition 132 may be provided an intended amount oftension or sag prior to being secured. For example, a predeterminedamount of the polymeric film composition 132 may extend into the moldcavity prior to the placement of the compression ring 246. The excesspolymeric film composition 132 in the mold cavity prior to securementmay limit an amount of elongation that is needed from the polymeric filmcomposition 132 to form the liner of the mold cavity.

FIG. 10 depicts a cross section of FIG. 9 after the polymeric filmcomposition 132 has been drawn down as a liner of the mold cavity 202,in accordance with aspect hereof. The compression ring 246 compressesthe polymeric film composition 132 between the inner ring 204 at the topsurface 226. As the polymeric film composition 132 transitions from thesidewalls, such as the lateral sidewall 218 to the top surface 226, thetrimmed portion 133 is formed from the polymeric film composition 132.The trimmed portion 133 is the portion of the polymeric film composition132 that is not joined with the polymeric foam composition 130 and thatwill be trimmed as depicted in FIG. 19 hereinafter.

FIG. 11 depicts an additional polymeric film composition 132 securementoption over the mold cavity, in accordance with aspects hereof. In thisexample, a vacuum pressure is applied to the polymeric film composition132 outside of the mold cavity 202 and prior to the polymeric filmcomposition 132 being drawn into the mold cavity 202 to form a liner. Aseries of apertures extend through the inner ring as vacuum ports 224.The vacuum apertures are conduits for vacuum that apply aid in securingthe polymeric film composition 132 to the top surface 226.

FIG. 12 depicts a cross section of FIG. 11 after the polymeric filmcomposition 132 has been drawn down as a liner of the mold cavity 202,in accordance with aspects hereof. In this example, it is contemplatedthat the polymeric film composition 132 is positioned over the moldcavity and concurrently or subsequently a vacuum is drawn through thevacuum ports 224 that create a securement force by vacuum at the topsurface 226 of the polymeric film composition 132. Once the polymericfilm composition 132 is secured to the mold 200 by the vacuum port 224,the bottom plate vacuum ports 222 may draw a vacuum there through toelongate and pull the polymeric film composition 132 into the moldcavity to form a liner. While the polymeric film composition 132 isbeing pulled down to form a liner, the polymeric film composition 132 issecured at the top surface by continued vacuum from the vacuum port 224.

The vacuum ports may be positioned as a plurality of ports extendingaround the mold cavity perimeter. The vacuum ports 224 may be spacedevery 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or more.Depending on a size of the vacuum port 224, the amount of vacuumpressure, the material characteristics, and the mold cavity size, thepositioning and spacing of the vacuum ports may be adjusted. Further, itis contemplated that the vacuum ports 224 are positioned closer togetherat regions of the mold cavity having a longer sidewall surface. As agreater elongation may occur for the longer sidewall pull, a strongersecurement is contemplated. For example, in a heel region having athicker polymeric foam composition from the ground-facing surface to theupper-facing surface thank in a toe region, the perimeter of the moldcavity near the heel region has a higher concentration of vacuum ports224 than in the perimeter of the toe region, for example.

Aspects herein contemplated a variable vacuum securement force generatedthrough the vacuum ports 224. As will also be discussed with respect toa magnetic securement technique provided in FIGS. 13-14 hereinafter, thevariable vacuum securement force may ensure unintended elongation of thepolymeric film composition 132 is limited by allowing intentionalslippage of the polymeric film composition 132 along the inner ring 204during the drawing of the polymeric film composition 132 in to the moldcavity as a liner. For example, one or more of the vacuum ports used forsecuring the polymeric film composition 132 may reduce a vacuum pressureapplied at different processes of the operation. In an example, as thepolymeric film composition 132 is heated, a first securement force isgenerated by the vacuum ports 224. At least partially through the vacuumdraw of the polymeric film composition 132 into the mold cavity, asecond securement force is generated by the vacuum ports 224. The secondsecurement force is less than the first securement force to allowslippage of the polymeric film composition 132 along the inner ring 204.This slippage allows for a formation of a liner of the mold cavity whilealso preventing over elongation of the polymeric film composition thatcould affect a visual characteristic of the polymeric film composition.Examples of affected visual characteristics include, but are not limitedto, a distortion or other deformation of a graphic or text element onthe polymeric film composition 132. Another example includes adimensional texture on the polymeric film composition 132 that is mutedor otherwise lessened by over elongation. As such, aspects contemplateallow for intentional slippage of at a least a portion of a polymericfilm composition relative to the mold to limit unintended visualcharacteristic effects.

FIG. 13 depicts a fourth exemplary technique for securing the polymericfilm composition 132 to the mold using magnetic attraction between amagnetic ring 251 and the inner ring 204, in accordance with aspectshereof. The magnetic attraction may be generated through any combinationof magnetic force, such as magnets 253 incorporated in the magnetic ring251, magnets 255 (as seen in FIG. 14A hereinafter) incorporated in theinner ring 204, magnetized magnetic ring 251, and/or magnetized innerring 204. Further, the magnetic attraction may be magnetic materialsand/or electromagnetic systems that generate a magnetic force inresponse to electrical input.

The magnetic ring 251 may be any shape. In an exemplary aspect themagnetic ring 251, as depicted, is a ring-like structure that iseffective to cover at least the edge of the inner ring 204 that definesthe mold cavity 202. For example, the magnetic ring may have a widthfrom an interior perimeter (e.g., central aperture) to an exteriorperimeter of 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, and greater. The greaterthe width, the more universal the magnetic ring 251 may be for differentsized molds and different styles of molds. Therefore, a universalmagnetic ring 251 configuration all for the number of magnetic ring 251variations to be limited to increase efficiency and reduce toolinginventory. However, it is contemplated that the magnetic ring 251includes at least one aperture, in an exemplary aspect, that allows forair to pass through the magnetic ring 251, such as in a central regionover the mold cavity 202. This aperture allows for pressure to beequalized to ambient pressure on a top surface of the polymeric filmcomposition 132 as the polymeric film composition 132 is drawn into themold cavity 202 to form a liner. The aperture extending through themagnetic ring 251 allows a pressure differential to be formed across thepolymeric film composition 132 as the vacuum is drawn through the bottomplate 208, as seen in FIG. 14A.

The magnetic ring 251 may be constructed from any material. Similar tothe compression ring 246, the magnetic ring 251 is formed from amaterial, such as steel, other ferrous metals, aluminum,polytetrafluoroethylene, other polymers, and the like. Because aspectscontemplate heating the polymeric film composition 132, the magneticring 251 is formed from a material that tolerates thermal cycles withtemperatures exceeding 200 Celsius. Depending on the magnetic attractionconfiguration, the magnetic ring 251 may be formed from a ferrousmaterial or at least incorporate a ferrous material. For example, if apermanent magnet, electric magnet, or other source of magnetic energy isincorporated with the inner ring 204, the magnetic ring 251 may be apassive component that is attracted to the magnetic energy source withinthe inner ring 204. Additionally or alternatively, the magnetic ring 251may include a magnetic energy source, such as a permanent magnet, anelectromagnet, or other magnetic energy source. Regardless of themagnetic energy source and position, it is contemplated that acompressive force is generated between the magnetic ring 251 and thering 204 around the perimeter of the mold cavity 202 using magneticattraction between the magnetic ring 251 and the ring 204.

As depicted in FIG. 13, a plurality of the magnets 253 are positionedaround a circumference of the magnetic ring 251 and within the width ofthe magnetic ring between the exterior perimeter and the centeraperture. Each of the magnets may have a common polarity orientationwithin the magnetic ring 251 to allow for varied positioning and astandardized attraction to a mold. Alternatively, it is contemplatedthat the polarity orientation of each of the magnets 253 may be variedto provide a self-alignment characteristic of the magnetic ring 251 tothe underlying mold. If magnets, such as the plurality of magnets 253,are incorporated within the magnetic ring 251, any number of magnets maybe used. For example, 4, 6, 8, 10, 12, 14, or any number of magnets maybe incorporated. Further, it is contemplated that an even spacing or anirregular spacing may be implemented in the positioning of the magnetsin the magnetic ring 251. A uniform spacing between the magnets 253 mayaid in providing a uniform compression around a perimeter. An irregularpositioning of the magnets 253 may be leveraged to achieve greatermagnetic compressive force in a specific location, such as where thecompressed polymeric film composition 132 is more prone to elongation.As will be depicted in FIG. 14B, it is also contemplated that themagnets may be omitted from the magnetic ring in some aspects. As themagnetic ring may be constructed having a ferrous metal, magnetic energysource (e.g., permanent magnet or electromagnet) may be in the molditself and generate a compressive force on the polymeric filmcomposition 132 through a magnetic attraction to the magnetic ringcontaining a ferrous metal.

FIG. 14A depicts a cross section view of the film securement using themagnetic ring 251 of FIG. 13, in accordance with aspects hereof. Similarto the aspects previously discussed with connection to FIGS. 10 and 12,the polymeric film composition 132 is secured during a vacuum draw intothe mold cavity formed at least by the ring 204 and the bottom plate208. At the top surface 226 of the ring 204 the magnetic ring 251compresses the polymeric film composition 132. The compressive force isgenerated through a magnetic attraction. The magnetic attraction may begenerated as a result of attractive polarities of opposing magnets 255in the ring 204 and the magnets 253 of the magnetic ring 251. Or, aspreviously discussed, one or more of the ring 204 and the magnetic ring251 may be attracted to a magnetic energy source. For example, the ring204 and/or the magnetic ring 251 may include a ferrous material (orother magnetically attracted material) that is attracted to an opposingmagnetic energy source.

The magnets 255 may be positioned at any location of the mold, but inthe illustrated example the magnets 255 are incorporated at the topsurface 226. The positioning of the magnets 255 may be aligned with thepositioning of the magnets 253 of the magnetic ring 251. Thiscoordination and alignment of the magnets 255 and the magnets 253 allowsfor an efficient use of magnetic energy potential between the magnets255 and the magnets 253.

Similar to the vacuum pressure securement technique of FIGS. 11-12, itis contemplated that the magnetic securement technique of FIGS. 13-15may be applied as a variable securement. If the magnetic compression isgenerated, at least in pa, through an electromagnetic source, the forcegenerated by the electromagnetic source may be adjusted during aprocess. For example, it is contemplated that the magnetic ring 251 maysecure the polymeric film composition 132 to the mold prior to heatingthe polymeric film composition 132. During the heating process a firstcompression is generated between the magnetic ring 251 and the mold.During a vacuum draw process, a second compression may be generatedbetween the magnetic ring 251 and the mold. The first compression may begreater than the second compression to allow for the polymeric filmcomposition 132 to not only elongate during the vacuum draw, but to alsoslidably move between the magnetic ring 251 and the mold. Selectivelyadjusting a timing and/or positioning of compressive force applied tothe polymeric film composition 132 may effectively limit unintendeddeformation of the polymeric film composition 132. Examples include thepolymeric film composition having a graphic or other element (text)visible on the surface such that an irregular or over-elongationdistorts the visual impression of the polymeric film composition.Another example includes a polymeric film composition having asdimensional texture. Excessive elongation of the dimensionally texturedpolymeric film composition can reduce and distort the dimensionaltexture. Consequently, aspects contemplate reducing a compressive forcebetween the magnetic ring 251 and the mold through an adjustment ofmagnetic force generated, such as a force generated by an electromagnet.The adjustment of compression, in this example, allows for intentionalslippage and limited elongation of the polymeric film composition 132.

An exemplary use of the magnetic ring 251 technique includes positioningthe polymeric film composition 132 over the mold cavity 202. Themagnetic ring 251 is then positioned over the polymeric film composition132 and in proximity to the mold. A magnetic attraction between themagnetic ring 251 and the mold results in a compression of the polymericfilm composition 132 between the mold and the magnetic ring 251 thatsecure the polymeric film composition 132 for being drawn into the moldcavity 202. After the polymeric film composition 132 is drawn into themold cavity 202, the magnetic ring 251 may be removed from the polymericfilm composition 132. The upper may then be positioned at the mold for adirect bottoming operation.

FIG. 14B depicts an alternative configuration for the magnetic ring 251in a cross section, in accordance with aspects hereof. Specifically, themagnetic ring 251 of FIG. 14B is constructed from a ferrous metal, suchas steel. Magnetic ring may be cut from the materials, such as a sheetof steel. The magnetic ring may have a thickness of 1-4 mm in a firstaspect and a thickness of 2-3 mm in a second aspect. The ferrousmagnetic ring is attracted or more magnetic energy sources (e.g.permanent magnet, electromagnet) at the mold, such as the ring 204. Themagnetic energy source may be countersunk into the top surface of thering 204. The magnetic ring 251 may be any shape. In an exemplaryaspect, the magnetic ring 251 has an exterior perimeter that is at leastas big and shape to extend outside of the mold cavity at the top surfaceof the inner ring 204. Stated differently, the size and shape of theinner ring 204 is sufficient to compress the polymeric film composition132 at the top surface of the ring 204.

FIG. 15 depicts the heat source 228 heating the polymeric filmcomposition 132, in accordance with aspects hereof. For example, aftersecuring the polymeric film composition 132 to the mold by any method,such as those methods provided in FIGS. 9-14 and prior to applying avacuum to draw the polymeric film composition 132 into the mold cavity,the heat source 228 may heat the polymeric film composition 132. Onceheated, the polymeric film composition 132 is more prone to elongationby a vacuum draw through the mold cavity. Further, as a result ofheating by the heat source 228, the polymeric film composition 132 maybe more compliant to the mold surfaces to result in a higher resolutionof detail that is captured by the polymeric film composition 132 fromthe mold surfaces and molded into sole 104.

FIG. 16 depicts the polymeric film composition 132 drawn down into themold cavity to form a liner of the mold cavity, in accordance withaspects hereof. While film apertures 248 are depicted, it is understoodthat any securement technique may be implemented and the illustratedtechnique is not limiting. With the polymeric film composition 132 drawndown by vacuum through the bottom plate, the medial film edge 134 andthe lateral film edge 136 are exposed and represent a location wheretrimming will be performed to create the trimmed portion 133. In thisstep, the vacuum may be maintained for a predefined period of time toensure acceptable contact between the polymeric film composition 132 andthe mold surfaces. Alternatively, the vacuum may cease once thepolymeric film composition 132 reaches a predefined temp that is lowerthan at the start of applying the vacuum to draw the polymeric filmcomposition 132 down as a liner. Additionally, the vacuum may bemaintained through subsequent processing steps, such as injection of thepolymeric foam composition.

FIG. 17 depicts a step of applying the upper 102 to a last 240 in a stepcommonly referred to as lasting, in accordance with aspects hereof. Thelast 240 is a tool that provides a defined shape to the upper 102 suchthat after the direct bottoming process, the upper 102 maintains asimilar shape, at least in part, as a result of the engagement with theresilient sole. The plantar region 114 is prominently illustrated inthis example. As discussed, the plantar region 114 will form theengagement surface for the sole during the direct bottoming process tofollow.

FIG. 18 depicts the lasted upper 102 being positioned relative to themold 200, in accordance with aspects hereof. The outer ring 206 isseparated by the actuators provided in FIG. 4. The slit outer ringconfiguration allows for the positioning of the upper 102 in the mold200 as intended to expose the plantar region to the molding cavity fordirect bottoming to occur.

FIG. 19 depicts the outer ring 206 in the closed configuration fordirect bottoming to the lasted upper 102, in accordance with aspectshereof. When in the closed configuration, the outer ring 206 compressesthe lasted upper to form a seal at the transition from the sole to bedirect bottomed and the upper 102. The injector 232 is positioned at themold to inject a composition into the mold cavity that will foam and bethe polymeric foam composition 130 discussed herein. While not depicted,it is contemplated that after the injector 232 injects the polymericfoam composition 130, the bottom plate raises to obscure the channelthrough which the polymeric foam composition 130 passed to reach themold cavity. This obstruction seals the mold cavity to contain theexpanding polymeric foam composition 130 within the mold cavity definedby the mold 200 and the secured upper 102. As provided previously thepolymeric foam composition 130 and the polymeric film composition 132may bond, mechanically and/or chemically as the polymeric foamcomposition 130 cures in the mold cavity in contact with the polymericfilm composition 132.

FIG. 20 depicts a ground-contacting surface of the article of footwear100 following the direct bottoming operation of FIG. 19, in accordancewith aspects hereof. Depicted is the trimmed portion 133 of thepolymeric film composition 132 prior to being trimmed. Also depicted isthe polymeric film composition 132 as exposed through the outsoleapertures 140 of the outsole 138.

FIG. 21 depicts a trimming operation of the polymeric film composition132, in accordance with aspects hereof. A cutting tool 242 is effectiveto cut the polymeric film composition 132 to spate the trimmed portion133 from the sole. The cutting tool 242 may be any cutting tool, such asa knife, hot wire, laser, and the like. In an exemplary aspect, thecutting tool is an oscillating cutter that rests against the surface tobe trimmed and cuts the material as the article is moved past thecutting portion. As the trimmed portion 133 is removed, the location ofthe cut forms the film edge, such as the lateral film edge 136 in theexemplary aspect. Below the lateral film edge 136, in the inferiordirection, is the polymeric film composition 132 forming an exteriorsurface of the sole. Above the lateral film edge 136, in the superiordirection, is the lateral exposed portion 137.

The trimming operation produces a crisp and definite transition betweenthe polymeric film composition 132 and the polymeric foam composition130. Therefore, a painting or printing operation is avoided to provide aprecise transition between the materials.

FIG. 22 depicts an alternative operation of inserting an insert 142prior to direct bottoming the upper 102, in accordance with aspectshereof. In this example, the polymeric film composition 132 has beenformed into a liner in the mold cavity and prior to injection thepolymeric foam composition 130; the insert 142 is positioned in the moldcavity. In this example, an air bag to assist in impact attenuation andfunction of the sole is provided; however, as provided herein above, theinsert may be a variety of materials and functions. Further, the insertmay be positioned at a variety of location within the mold cavity, suchas the arch, the ball region, and a combination of region. Further, aspreviously discussed, it is contemplated that any number of inserts ofany combination of functions may be inserted into the mold cavity to beincluded during the direct bottoming process.

While the insert 142 is depicted as being placed into the mold cavityprior to positioning the upper 102 at the mold, it is contemplated thatthe insert 142 may alternatively be positioned at the mold with theupper 102. For example, the insert 142 may be temporarily or permanentlysecured to the upper 102 such that when the upper 102 is positioned atthe mold, the insert 142 is also positioned at the mold. In aspects,some inserts when placed in the mold cavity prior to injecting thepolymeric foam composition may interfere with an injection stream of thepolymeric foam composition. Similarly, some inserts, such as an air bagor foam component may float on the injected foam composition and, as aresult, be repositioned prior to a solidification of the polymeric foamcomposition. Therefore, aspects contemplate injecting the polymeric foamcomposition into the lined mold cavity prior to the insertion of theinsert 142. The insertion may be incorporated with the positioning ofthe upper 102 or it may be a separate intervening step.

FIG. 23 depicts a flow diagram representing a method 2300 ofmanufacturing an article of footwear, in accordance with aspects hereof.At a block 2302 a film, such as the polymeric film composition 132 ofFIG. 1, is positioned over a mold cavity, such as the mold cavity 202 ofFIG. 4. The positioning of the film may be accomplished by a humanoperator or an automated machine, such as a robotic arm. The positioningmay be a mere placement or it may be an alignment that provides apredefined tension or sag to the film across the mold cavity. Referringto FIGS. 7, 9, and 11 provide examples of placing a film.

At a block 2304 the film is secured over the mold cavity. Exemplarytechniques for securing the film were discussed at least in connectionwith FIGS. 7-14 herein above.

At a block 2306 thermal energy is applied to the film. The thermalenergy may be in the form of infrared energy that is effective to heatthe film to an elevated temperature that is below a glass transitiontemperature of the film. The elevated temperature allows for sufficientelongation of the film during a drawing process into the mold cavity.

At a block 2308 a vacuum is drawn through the mold cavity to form aliner of the mold cavity with the film. Because the film was secured inthe block 2304, the vacuum causes a deformation of the film from apressure differential on the opposing sides of the film. This pressuredifferential allows the film to be drawn into the mold cavity andconform to the mold surfaces.

At a block 2310 a material composition, such as the polymeric foamcomposition 130 of FIG. 1 is injected into the lined mold cavity. As themold cavity is a sealed environment, the material expands and forms tothe mold surfaces. In addition to forming to the mold surfaces, thematerial mechanically engages and intermingles with materials of anupper positioned at the mold cavity, as listed at a block 2312. It isunderstood that the upper may be positioned at the mold cavity prior toinjecting the material. Therefore the order of the block 2310 and theblock 2312 may be altered in various aspects. Regardless of the order ofoperation, the intermingling and interaction of the foamed material andthe upper, the result is a bond is formed between the upper and thenow-created sole. This bond is a direct bottoming operation thateliminates, in some aspect the use of adhesive to join the upper withthe sole. Instead the creation of the sole itself results in a joiningof the sole with the upper.

At a block 2314 the article of footwear formed in the preceding blocksis removed from the mold cavity. In some aspects the mold may split orotherwise open to allow for the removal of the article of footwear fromthe mold.

At a block 2316 the film is trimmed from the sole such that an exposedportion (a portion of the foamed material not covered in the film) isformed between the film and the upper on the sole sidewall. This exposedportion may be at least 1 mm. The exposed portion may have a range of 1mm to 10 mm, in exemplary aspect. The exposed portion may be in a rangeof about 2 mm to 6 mm. Regardless, the exposed portion provides an areafor the trimming operation to occur without interference from the upper.Further, the exposed region provides an aesthetic differentiator alongthe sidewall while still allowing the film to provide functionaladvantages discussed herein above along the sidewall(s).

As can be appreciated, the methods of forming the article of footwearprovided herein are conducive to custom manufacturing. For example, itis contemplated that in a continuous manufacturing process differentarticle of footwear are produced having different characteristics. Forexample, a first article of footwear may have a first visualcharacteristic and an immediately subsequently manufactured article offootwear has a different visual characteristic. This may be accomplishedby inserting an alternative film while keeping other parametersconstant. The alternative film may have a different color, texture,graphic, and the like. Further, it is contemplated that a differentpolymeric foam composition may be used on the first article of footwearas compared to the immediate subsequent article of footwear. For examplea different additive, such as a colorant, may be incorporated with thepolymeric foam composition at injection. This is different fromtraditional shoe manufacturing that maintains an inventor of both theupper and the sole to be joined. With the contemplated direct bottomingoperation, the sole is manufactured at the time of joining. As a result,the manufactured sole may be customized as needed without keeping aninventory of different soles. Beyond visual characteristics that may becustomized, the function of the sole may be customized through theinclusion of one or more inserts, as provided herein.

Further, as the film, such as the polymeric film composition, iseffective to cure tooling marks formed by the mold and other tools,interchangeable mold components may be used. Traditionally, aninterchangeable mold portion results in a tooling mark in the formedarticle as a result of a transition from the mold surface to theinterchangeable component surface, which can generate a line at thattransition. In the contemplated methods herein, the film cures thepotential tooling marking by normalizing the surface transition betweenthe mold surface and the interchangeable component surface. It is thisnormalization that allows for the interchangeable portions to beexchanged in a common mold to customize the formed sole. Theinterchangeable component may an embossments (e.g., positive space inthe molded article) or debossments (e.g., negative space in the moldedarticle) that generate logos, graphics, textures, and the like. As aresult, a continuously operating manufacturing line may producedifferent article of footwear through the selection of films, foams,interchangeable components in the mold, and/or the like.

For convenience, a listing of features provided in FIGS. 1-22 isprovided below.

-   -   Article of footwear—100    -   Upper—102    -   Upper medial side—106    -   Upper lateral side—108    -   Upper toe end—110    -   Upper heel end—112    -   Upper plantar region—114    -   Sole—104    -   Sole medial side—116    -   Sole lateral side—118    -   Sole toe end—120    -   Sole heel end—122    -   Upper-facing surface—123    -   Ground-facing surface—124    -   Medial sidewall—126    -   Lateral sidewall—128    -   Polymeric foam composition—130    -   Polymeric film composition—132    -   Trimmed portion—133    -   Medial film edge—134    -   Medial exposed portion—135    -   Lateral film edge—136    -   Lateral exposed portion—137    -   Outsole—138    -   Outsole aperture—140    -   Insert—142    -   First distance [at ground-facing surface]—144    -   Second distance [at the upper-facing surface]—146    -   Mold—200    -   Mold cavity—202    -   Inner ring—204    -   Outer ring—206    -   Bottom plate—208    -   First molding surface—210    -   Second molding surface—212    -   Medial sidewall of inner ring—214    -   Medial sidewall of outer ring—216    -   Lateral sidewall of inner ring—218    -   Lateral sidewall of outer ring—220    -   Bottom plate vacuum port—222    -   Inner ring vacuum port—224    -   Inner ring top surface—226    -   Heat source—228    -   Vacuum source—230    -   Injector—232    -   Material source—234    -   Robotic arm—236    -   Film source—238    -   Last—240    -   Cutting tool—242    -   Compression ring—246    -   Film aperture—248    -   Mold securement—250    -   Magnetic ring—251    -   Outside the mold cavity—252    -   Ring magnet—253    -   Removable molding element—254    -   Mold magnet—255    -   Vision system—256    -   Bottom plate actuator—258    -   Outer ring medial actuator—260    -   Outer ring lateral actuator—262

The following are example clauses representing aspects contemplatedherein.

1. An article of footwear comprising: an upper comprising: a medialside, a lateral side, a toe end, a heel end, and a plantar regionextending between the medial side, the lateral side, the toe end, andthe heel end; and a sole having a medial side, a lateral side, a toeend, a heel end, an upper-facing surface extending between the medialside, the lateral side, the toe end, and the heel end, a ground-facingsurface opposite the upper-facing surface, a medial sidewall extendingbetween the ground-facing surface and the upper facing surface along themedial side, and a lateral sidewall extending between the ground-facingsurface and the upper-facing surface along the lateral side, the solecomprising: a polymeric foam composition forming at least a portion ofthe upper-facing surface and mechanically engaged with the upper plantarregion; and a polymeric film composition forming at least a portion ofthe medial side wall from the ground-facing surface toward the upper ata medial film edge and also forming at least a portion of the lateralside wall from the ground-facing surface toward the upper at a lateralfilm edge, wherein there is at least 1 mm between the upper-facingsurface at the medial sidewall and the medial film edge and there is atleast 1 mm between the upper-facing surface at the lateral sidewall andthe lateral film edge.

2. The article of footwear of clause 1 further comprising an outsole,the outsole coupled with the ground-facing surface.

3. The article of footwear of clause 2, wherein the outsole is coupledwith the film composition on the ground-facing surface of the sole.

4. The article of footwear of clause 3, wherein an adhesive couples theoutsole and the film composition.

5. The article of footwear of clause 2, wherein the outsole is comprisedof an aperture extending through the outsole to the film composition onthe ground-facing surface.

6. The article of footwear of clause 2, wherein the sole furthercomprises an insert, the insert at least partially encased by thepolymeric foam composition and the polymeric film composition.

7. The article of footwear of clause 1, wherein the medial sidewallangles toward the lateral sidewall as the medial sidewall extends fromthe ground-facing surface toward the upper-facing surface between thetoe end and the heel end.

8. The article of footwear of clause 1, wherein a first distance betweenthe medial sidewall and the lateral sidewall at the ground-facingsurface is greater than a second distance between the medial sidewalland the lateral sidewall at the upper-facing surface.

9. The article of footwear of clause 1, wherein the polymeric foamcomposition comprises a polyurethane composition and the polymeric filmcomposition comprises a thermoplastic polyurethane composition.

10. The article of footwear of clause 1, wherein the polymeric filmcomposition extends between the medial sidewall and the lateral sidewallon the ground-facing surface.

11. The article of footwear of clause 1, wherein the polymeric foamcomposition forms the medial side wall between the medial film edge andthe upper-facing surface and the polymeric foam composition forms thelateral side wall between the lateral film edge and the upper-facingsurface.

12. The article of footwear of clause 1, wherein the polymeric filmcomposition has a different visual characteristic than the polymericfoam composition on at least the medial sidewall.

13. A method of making an article of footwear, the method comprising:

positioning a polymeric film composition over a mold cavity of a moldhaving a first molding surface forming a ground-facing surface of afootwear sole, and a second molding surface forming a sidewall of thefootwear sole; securing the polymeric film composition over the moldcavity to enclose the mold cavity; applying thermal energy to thepolymeric film composition; drawing a vacuum through the mold cavityenclosed by polymeric film composition until at least a portion of thepolymeric film composition contacts the first molding surface and thesecond molding surface as the polymeric film composition forms a linerfor at least a portion of the mold cavity; injecting a materialcomposition that will foam as a polymeric foam composition into the moldcavity with the polymeric film composition as the liner of at least aportion of the mold cavity; positioning a footwear upper at the moldcavity, wherein the footwear upper is positioned such that the polymericfoam composition mechanically engages with the footwear upper to formthe article of footwear; removing the article of footwear from the moldcavity; and trimming the polymeric film composition from at least thesidewall, wherein the polymeric film composition extends up to a filmedge on the sidewall that is at least 1 mm from the upper.

14. The method of manufacturing an article of footwear of clause 13,wherein the polymeric foam composition comprises a polyurethanecomposition and the polymeric film composition comprises a thermoplasticpolyurethane composition

15. The method of manufacturing an article of footwear of clause 13,wherein the positioning of the polymeric film composition comprises arobotic arm securing the polymeric film composition, moving thepolymeric film position, and depositing the polymeric film compositionover the mold cavity.

16. The method of manufacturing an article of footwear of clause 13,wherein securing the polymeric film composition comprises: positioning aring over the polymeric film composition; and compressing the polymericfilm composition between mold and the ring.

17. The method of manufacturing an article of footwear of clause 13,wherein securing the polymeric film composition comprises securing anaperture extending through the polymeric film composition with a portionof the mold.

18. The method of manufacturing an article of footwear of clause 17,wherein the portion of the mold to which the polymeric film aperture issecured is selected from a pin or a hook.

19. The method of manufacturing an article of footwear of clause 13,wherein securing the polymeric film composition comprises applying avacuum pressure to the polymeric film composition outside of the moldcavity to secure the polymeric film composition to the mold.

20. The method of manufacturing an article of footwear of clause 13further comprising, prior to positioning the polymeric film composition,inserting a removable molding element into the sidewall of the moldcavity.

21. The method of manufacturing an article of footwear of clause 13,wherein the mold cavity forms angled sidewalls of the footwear sole asthe sidewalls extend from the ground-facing surface.

22. A method of manufacturing a plurality of different articles offootwear with a common mold, the method comprising: positioning a firstpolymeric film composition over a mold cavity of a mold having a firstmolding surface forming a ground-facing surface of a footwear sole, anda second molding surface forming a sidewall of the footwear sole;securing the first polymeric film composition over the mold cavity toenclose the mold cavity; drawing a vacuum through the mold cavityenclosed by first polymeric film composition until at least a portion ofthe first polymeric film composition contacts the first molding surfaceand the second molding surface as the first polymeric film compositionforms a first liner for at least a portion of the mold cavity;positioning a first footwear upper at the mold cavity, wherein the firstfootwear upper is positioned such that an injected polymeric foamcomposition mechanically engages with the first footwear upper to form afirst article of footwear comprised of the first polymeric filmcomposition, the polymeric foam composition, and the first upper;removing the first article of footwear from the mold cavity; positioninga second polymeric film composition over the mold cavity, wherein thesecond polymeric film composition has a different visual characteristicthan the first polymeric film composition; securing the second polymericfilm composition over the mold cavity to enclose the mold cavity;drawing a vacuum through the mold cavity enclosed by second polymericfilm composition until at least a portion of the second polymeric filmcomposition contacts the first molding surface and the second moldingsurface as the second polymeric film composition forms a second linerfor at least a portion of the mold cavity; positioning a second footwearupper at the mold cavity, wherein the second footwear upper ispositioned such that an injected polymeric foam composition mechanicallyengages with the second footwear upper to form a second article offootwear comprised of the second polymeric film edger, the polymericfoam composition, and the second footwear upper; and removing the secondarticle of footwear from the mold cavity.

23. An article of footwear mold comprising: an inner ring mold having aninner medial sidewall molding surface and an inner lateral sidewallmolding surface; an outer ring mold having an outer medial sidewallmolding surface and an outer lateral sidewall molding surface, whereinthe inner medial sidewall molding surface and the outer medial sidewallmolding surface in combination form a medial sidewall molding surface ofthe article of footwear mold and the inner lateral sidewall moldingsurface and the outer lateral sidewall molding surface in combinationform a lateral sidewall molding surface of the article of footwear mold:and a bottom plate positioned between the inner medial sidewall moldingsurface and the inner lateral sidewall molding surface.

24. The article of footwear mold of clause 23 further comprising apolymeric film composition securement.

25. The article of footwear mold of clause 24, wherein the polymericfilm composition securement comprises a plurality of pins extending fromthe inner ring mold, wherein at least a pin is located on a medial sideof the inner ring mold, at least a pin is located on a lateral side ofthe inner ring mold, at least a pin is located on a toe end of the innerring mold, and at least a pin is located on a heel end of the inner ringmold.

26. The article of footwear mold of clause 24, wherein the polymericfilm composition securement comprises a plurality of protrusionsextending from the inner ring mold.

27. The article of footwear mold of clause 24, wherein the polymericfilm composition securement comprises a vacuum port at a top surface ofthe inner ring mold.

28. The article of footwear mold of clause 27 wherein at least a vacuumport is located on the top surface at a medial side of the inner ringmold, at least a vacuum port is located on the top surface at a lateralside of the inner ring mold, at least a vacuum port is located on thetop surface at a toe end of the inner ring mold, and at least a vacuumport is located on the top surface at a heel end of the inner ring mold.

29. The article of footwear mold of clause 23, wherein the bottom plateis comprised of a vacuum port extending through the bottom plate to abottom plate top surface.

30. The article of footwear mold of clause 29 further comprising avacuum port at a top surface of the inner ring mold.

31. The article of footwear mold of clause 30, wherein the vacuum portat the top surface of the inner ring mold is operatively coupled with avacuum source and the vacuum port extending through the bottom plate isoperatively coupled with a vacuum source.

32. The article of footwear mold of clause 31, wherein the vacuum portat the top surface of the inner ring mold is independently operable fromthe vacuum port extending through the bottom plate.

33. The article of footwear mold of clause 24, wherein the polymericfilm composition securement comprises a magnet at a top surface of theinner ring mold.

34. The article of footwear mold of clause 33 wherein the magnet is anelectromagnet.

35. The article of footwear mold of clause 33, wherein the magnet is apermanent magnet.

36. The article of footwear mold of clause 24, wherein the polymericfilm composition securement comprises a compression ring.

37. The article of footwear mold of clause 36, wherein the inner ringmold comprises a lip at a top surface and the compression ring isconfigured to fit around the lip.

38. The article of footwear mold of clause 23 further comprising amagnetic ring.

39. The article of footwear mold of clause 38, wherein at least one ofthe magnetic ring and the inner ring mold comprise a magnet.

40. The article of footwear mold of clause 38, wherein the magnetic ringcomprises a first magnet and the inner ring mold comprise a secondmagnet, wherein the first magnet and the second magnet magneticallyattract the magnetic ring to the inner ring mold.

41. The article of footwear mold of clause 23, wherein the inner medialsidewall molding surface and the inner lateral sidewall molding surfaceconverge as they extend away from the bottom plate toward an inner ringmold top surface.

42. The article of footwear mold of clause 23, further comprising afirst actuator coupled to a first half of the outer ring and a secondactuator coupled to a second half of the outer ring.

43. An article of footwear mold comprising: a mold having a medialsidewall molding surface and a lateral sidewall molding surface; apolymeric film composition securement: and a bottom plate positionedbetween the medial sidewall molding surface and the lateral sidewallmolding surface.

44. The article of footwear mold of clause 43, wherein the polymericfilm composition securement comprises a plurality of pins extending fromthe mold, wherein at least a pin is located on a medial side of themold, at least a pin is located on a lateral side of the mold, at leasta pin is located on a toe end of the mold, and at least a pin is locatedon a heel end of the mold.

45. The article of footwear mold of clause 43, wherein the polymericfilm composition securement comprises a plurality of protrusionsextending from mold.

46. The article of footwear mold of clause 43, wherein the polymericfilm composition securement comprises a vacuum port at a top surface ofthe mold.

47. The article of footwear mold of clause 46 wherein at least a vacuumport is located on the top surface at a medial side of the mold, atleast a vacuum port is located on the top surface at a lateral side ofthe mold, at least a vacuum port is located on the top surface at a toeend of the mold, and at least a vacuum port is located on the topsurface at a heel end of the mold.

48. The article of footwear mold of clause 43, wherein the bottom plateis comprised of a vacuum port extending through the bottom plate to abottom plate top surface.

49. The article of footwear mold of clause 48 further comprising avacuum port at a top surface of the mold.

50. The article of footwear mold of clause 49, wherein the vacuum portat the top surface of the mold is operatively coupled with a vacuumsource and the vacuum port extending through the bottom plate isoperatively coupled with a vacuum source.

51. The article of footwear mold of clause 50, wherein the vacuum portat the top surface of the mold is independently operable from the vacuumport extending through the bottom plate.

52. The article of footwear mold of clause 43, wherein the polymericfilm composition securement comprises a magnet at a top surface of themold.

53. The article of footwear mold of clause 52, wherein the magnet is anelectromagnet.

54. The article of footwear mold of clause 52, wherein the magnet is apermanent magnet.

55. The article of footwear mold of clause 43, wherein the polymericfilm composition securement comprises a compression ring.

56. The article of footwear mold of clause 55, wherein the moldcomprises a lip at a top surface and the compression ring is configuredto fit around the lip.

57. The article of footwear mold of clause 43 further comprising amagnetic ring.

58. The article of footwear mold of clause 57, wherein at least one ofthe magnetic ring and the mold comprise a magnet.

59. The article of footwear mold of clause 57, wherein the magnetic ringcomprises a first magnet and the mold comprise a second magnet, whereinthe first magnet and the second magnet magnetically attract the magneticring to the mold.

60. The article of footwear mold of clause 43, wherein the medialsidewall molding surface and the lateral sidewall molding surfaceconverge as they extend away from the bottom plate toward a mold topsurface.

Many different arrangements of the various components depicted, as wellas components not shown, are possible without departing from the spiritand scope of the present disclosure. Embodiments of the presentdisclosure have been described with the intent to be illustrative ratherthan restrictive. Alternative embodiments will become apparent to thoseskilled in the art that do not depart from its scope. A skilled artisanmay develop alternative means of implementing the aforementionedimprovements without departing from the scope of the present disclosure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations and are contemplated within the scope of the claims. Notall steps listed in the various figures need be carried out in thespecific order described.

The invention claimed is:
 1. An article of footwear comprising: an uppercomprising: (1) a medial side, a lateral side, a toe end, a heel end,and a plantar region extending between the medial side, the lateralside, the toe end, and the heel end; and a sole having a medial side, alateral side, a toe end, a heel end, an upper-facing surface extendingbetween the medial side, the lateral side, the toe end, and the heelend, a ground-facing surface opposite the upper-facing surface, a medialsidewall extending between the ground-facing surface and the upperfacing surface along the medial side, and a lateral sidewall extendingbetween the ground-facing surface and the upper-facing surface along thelateral side, the sole comprising: (1) a polymeric foam compositionforming at least a portion of the upper-facing surface and mechanicallyengaged with the upper plantar region; and (2) a polymeric filmcomposition forming at least a portion of the medial side wall from theground-facing surface toward the upper at a medial film edge and alsoforming at least a portion of the lateral side wall from theground-facing surface toward the upper at a lateral film edge, whereinthere is at least 1 mm between the upper-facing surface at the medialsidewall and the medial film edge and there is at least 1 mm between theupper-facing surface at the lateral sidewall and the lateral film edge.2. The article of footwear of claim 1 further comprising an outsole, theoutsole coupled with the ground-facing surface.
 3. The article offootwear of claim 2, wherein the outsole is coupled with the filmcomposition on the ground-facing surface of the sole.
 4. The article offootwear of claim 3, wherein an adhesive couples the outsole and thefilm composition.
 5. The article of footwear of claim 2, wherein theoutsole is comprised of an aperture extending through the outsole to thefilm composition on the ground-facing surface.
 6. The article offootwear of claim 2, wherein the sole further comprises an insert, theinsert at least partially encased by the polymeric foam composition andthe polymeric film composition.
 7. The article of footwear of claim 1,wherein the medial sidewall angles toward the lateral sidewall as themedial sidewall extends from the ground-facing surface toward theupper-facing surface between the toe end and the heel end.
 8. Thearticle of footwear of claim 1, wherein a first distance between themedial sidewall and the lateral sidewall at the ground-facing surface isgreater than a second distance between the medial sidewall and thelateral sidewall at the upper-facing surface.
 9. The article of footwearof claim 1, wherein the polymeric foam composition comprises apolyurethane composition and the polymeric film composition comprises athermoplastic polyurethane composition.
 10. The article of footwear ofclaim 1, wherein the polymeric film composition extends between themedial sidewall and the lateral sidewall on the ground-facing surface.11. The article of footwear of claim 1, wherein the polymeric foamcomposition forms the medial side wall between the medial film edge andthe upper-facing surface and the polymeric foam composition forms thelateral side wall between the lateral film edge and the upper-facingsurface.
 12. The article of footwear of claim 1, wherein the polymericfilm composition has a different visual characteristic than thepolymeric foam composition on at least the medial sidewall. 13-20.(canceled)